Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D3/00—Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping
  • B01D3/34—Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping with one or more auxiliary substances
  • B01D3/36—Azeotropic distillation
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
  • C07C29/74—Separation; Purification; Use of additives, e.g. for stabilisation
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
  • C07C29/74—Separation; Purification; Use of additives, e.g. for stabilisation
  • C07C29/76—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment
  • C07C29/80—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment by distillation
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
  • C07C29/74—Separation; Purification; Use of additives, e.g. for stabilisation
  • C07C29/76—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment
  • C07C29/80—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment by distillation
  • C07C29/82—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment by distillation by azeotropic distillation
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
  • C07C29/74—Separation; Purification; Use of additives, e.g. for stabilisation
  • C07C29/76—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment
  • C07C29/86—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment by liquid-liquid treatment
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
  • C07C29/74—Separation; Purification; Use of additives, e.g. for stabilisation
  • C07C29/76—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment
  • C07C29/78—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment by condensation or crystallisation

Definitions

• This invention relates to the use of an olefin as an azeotropic entrainer to isolate a target organic compound. More particularly, this invention relates to processes and apparatuses for using an olefin, such as 1-decene, 1-dodecene, or 1 -tetradecene, as an azeotropic entrainer to isolate l,3-dichloro-2-propanol from a waste stream that includes 2,2'- oxybis( 1 -chloropropane).
• an olefin such as 1-decene, 1-dodecene, or 1 -tetradecene
• DCP l,3-dichloro-2-propanol
• DCP is a di- functional raw material that may be useful in various processes. It may be prepared by chlorination of glycerin (K. Kawahata, Y. Awano, Y. Hara, Japanese Patent Publication No. JP2010047492 (2010)), and is an intermediate in the production of epichlorohydrin, useful for the manufacture of epoxy resins, from glycerin (E. Van der Graaf, L. Gonclaves de Mendonca Filho, WO2010102368 (2010); D. Shi, X. Che, Z. Shen, Y. Song, L. Fu, P. Dong, J. Jin, Q. Zhou, B.
• DCP One low cost source of DCP is the distillation residue from a propylene oxide/propylene glycol process. Functionalization of propylene by hydrochlorination to generate propylene oxide and propylene dichloride also generates epichlorohydrin as a byproduct. Following recovery of the epichlorohydrin and other products by distillation, a waste stream, often referred to as the Crude PDC Bottoms, remains. Although the accessible amount of epichlorohydrin has been recovered from this waste stream, it still contains residual epichlorohydrin and other by-products.
• the residual epichlorohydrin in the Crude PDC Bottoms can be converted to DCP by reacting with hydrogen chloride.
• the isolation and purification of the DCP generated is difficult due to an azeotrope formation of DCP with 2,2'-oxybis(l- chloropropane), one of the major by-products of the propylene oxide/propylene glycol waste stream.
• An azeotrope is a mixture of two or more liquids in such a ratio that its composition cannot be changed by simple distillation, because when the solution is boiled, the vapor that results has the same ratio of constituents as the original liquid mixture.
• an illustrative embodiment provides a process comprising supplying a feed stream and an olefin stream to a first distillation column, the feed stream comprising a target organic compound; using the olefin as an entrainer in the first distillation column such that the feed stream is separated into at least a first top stream and a first bottom stream; and using a second distillation column to separate the first top stream into at least a second top stream and a second bottom stream.
• the second bottom stream may comprise the target organic compound and the olefin.
• the process may further comprise separating the second bottom stream in a separator to produce a third bottom stream and the olefin stream, wherein the third bottom stream comprises the target organic compound.
• the process may further comprise reacting the target organic compound in the second bottom stream with the olefin in the second bottom stream.
• an illustrative embodiment provides a process for isolating 1,3- dichloro-2-propanol, the process comprising supplying a feed stream which includes 1,3- dichloro-2-propanol and 2,2'-oxybis(l-chloropropane) to a first distillation column, supplying an olefin stream comprising an olefin to the first distillation column, and using the olefin as an entrainer in the first distillation column, such that the first stream is separated into at least a first top stream and a first bottom stream.
• the first top stream comprises 1,3- dichloro-2-propanol and the olefin and the first bottom stream comprises 2,2'-oxybis(l- chloropropane).
• the process further comprises supplying the first top stream to a second distillation column and using the second distillation column to separate the first top stream into at least a second top stream and a second bottom stream, wherein the second bottom stream comprises l,3-dichloro-2-propanol and the olefin, and the second top stream comprises lighter boiling impurities carried into the second column from the first top stream.
• the second bottoms stream is separated in a separator into at least a third bottom stream and a third top stream, wherein the third bottom stream comprises l,3-dichloro-2-propanol and the third top stream comprises the olefin. At least a portion of the third top stream is returned to the first distillation column as the olefin stream.
• an illustrative embodiment provides an apparatus for isolating l,3-dichloro-2-propanol from a feed stream comprising of 2,2'-oxybis(l-chloropropane) and l,3-dichloro-2-propanol.
• the apparatus comprises a first distillation column for separating the feed stream into at least a first top stream and a first bottom stream, using an olefin as an entrainer; and a second distillation column for separating the first top stream into a second top stream and a second bottom stream.
• Figure 1 is a schematic diagram of an apparatus for using an olefin as an entrainer to isolate a target organic compound, in accordance with an illustrative embodiment.
• Figure 2 is a graph of a vapor-liquid equilibrium model assessment of l,3-dichloro-2- propanol and 2,2'-oxybis(l-chloropropane).
• Figure 3 is a graph of a vapor-liquid equilibrium model assessment of l,3-dichloro-2- propanol and 1-decene.
• Figure 4 is a graph of a vapor-liquid equilibrium model assessment of 1,2,3- trichloropropane and 1-decene.
• Figure 5 is a graph of a gas chromatography/mass spectrometry (GC/MS) analysis of a l,3-dichloro-2-propanol/l-decene distillate fraction.
• GC/MS gas chromatography/mass spectrometry
• Figure 6 is a graph of a vapor-liquid equilibrium model assessment of l,3-dichloro-2- propanol and 1-dodecene.
• Figure 7 is a graph of a vapor-liquid equilibrium model assessment of 1,2,3- trichloropropane and 1-dodecene.
• Figure 8 is a graph of a vapor-liquid equilibrium model assessment of l,3-dichloro-2- propanol and 1 -tetradecene.
• Figure 9 is a graph of the vapor pressure of 1-octene as compared to 1,2- dichloropropane, epichlorohydrin, 2-methyl-2-pentenal, and l,3-dichloro-2 -propanol.
• a process for using an olefin as an entrainer in an azeotropic distillation column in order to isolate a target organic compound.
• FIG. 1 illustrates an apparatus, 100, for isolating a target organic compound.
• the target organic compound may be a waste product of another process.
• the target organic compound may be l,3-dichloro-2-propanol (DCP).
• DCP l,3-dichloro-2-propanol
• a possible source of DCP may be the distillation bottoms waste stream of a propylene oxide/propylene glycol process. This waste stream may contain residual epichlorohydrin, which can be converted to DCP by reacting with hydrogen chloride.
• a feed stream 101 and a first olefin stream 102 may be supplied to a first distillation column 103.
• the feed stream 101 may comprise 2,2'-oxybis(l-chloropropane) and 1,3- dichloro-2-propanol.
• the first olefin stream 102 may comprise an olefin, such as 1-decene, 1-dodecene, or 1 -tetradecene.
• the olefin may be a co-reactant in a further process, for example, a process for the etherification of DCP. (See, e.g., E. Daugs, D. Flick, C. Rand, M. Tulchinsky, W. Yu, United States Patent Application No.
• the ratio of the olefin stream 102 to the feed stream 101 may be about 0.01 or greater, more preferably about 0.05 or greater, and most preferably about 0.1 or greater. Further, the ratio of the olefin stream 102 to the feed stream 101 may be about 1 or less, more preferably about 0.5 or less, and most preferably about 0.3 or less.
• the first distillation column 103 may be an azeotropic distillation column, such as a heterogeneous azeotropic distillation column. Heterogeneous azeotropic distillation columns may be used to separate mixtures of close relative volatility and also to break up azeotropes.
• the first distillation column 103 may comprise a first condenser 104 and a first reboiler 105.
• the olefin may be used as an entrainer, such that the feed stream 101 is separated into at least a first top stream 106 and a first bottom stream 107.
• the olefin may form a minimum-boiling azeotrope with the target organic compound.
• the first top stream 106 may comprise the olefin and the target organic compound.
• the first bottom stream 107 may comprise a waste product, for example, 2,2'-oxybis(l- chloropropane).
• the first top stream 106 may be condensed in the first condenser 104 and then may be supplied to a second distillation column 108.
• the second distillation column 108 may be a conventional distillation column.
• the second distillation column 108 may comprise a second condenser 109 and a second reboiler 1 10.
• the second distillation column 108 may separate the first top stream 106 into at least a second top stream 1 1 1 and a second bottom stream 112.
• the second top stream 11 1 may comprise lighter boiling impurities such as 1,2-dichloropropane, residual epichlorohydrin, and 2-methyl-2-pentenal.
• the second bottom stream 1 12 may comprise a mixture of the olefin and the target organic compound.
• the second bottom stream 112 may be supplied to a separator 113, where the second bottom stream 112 may be separated into a third bottom stream 114 and the first olefin stream 102.
• the separator 113 may be a decanter and may use liquid-liquid phase separation due to the density difference between DCP (1300 kg/m 3 (1.3 g/cc)) and olefin (700-800 kg/m 3 (0.7- 0.8 g/cc)) and low mutual solubility.
• the third bottom stream 1 14 may comprise mostly the target organic compound.
• the first olefin stream 102 may return to the first distillation column 103.
• a second olefin stream 1 15 may be supplied to the separator 1 13 in order to replenish the olefin which may be lost in the first bottom stream 107 and the third bottom stream 1 14.
• the olefin and the target organic compound may react in a reactor (not shown) instead of entering the separator 113.
• Examples 2, 4, 5, and 6 are generated using ASPEN computer-aided process simulation software (Aspen Technology, Incorporated, Burlington, Massachusetts), which uses a database of measured physical properties for engineering design calculations.
• Examples 1 and 3 are from laboratory experiments.
• DCP l,3-Dichloro-2-propanol
• DCP is a di-functional raw material available from epichlorohydrin-based chemistries that can be used for synthesis of a family of developmental new surfactant products based on etherification with olefins.
• DCP is available, for example, by purification from an intermediate stream in a process to prepare epichlorohydrin from glycerin (B. Hook, D. Tirtowidjojo, A. Merenov, WO2009126415 (2009)), or by titration of epichlorohydrin with hydrogen chloride.
• DCP raw material is a waste stream from propylene oxide/propylene glycol (PO/PG) processes.
• This stream often referred to as the Crude PDC (propylene dichloride) Bottoms, while containing only trace levels of DCP, contains residual epichlorohydrin that may be converted to DCP by reaction with hydrogen chloride. The accessible quantity of epichlorohydrin has been recovered from this stream by distillation.
• Table 1 A summary of a typical stream composition of the Crude PDC Bottoms and the pure component boiling points at atmospheric pressure is shown in Table 1.
• Example 1 Preparation and distillation purification of DCP from the Crude PDC Bottoms without an azeotropic entrainer
• a 1-L jacketed bottom-drain glass reactor with an overhead stirrer and nitrogen bubbler is charged with 0.8877 kg (887.7 grams) of the Crude PDC Bottoms, and cooled to 15 degrees Celsius using an attached recirculating heater / chiller.
• GC analysis of the feed solution finds 1 1.8 area percent dichloropropane, 22.8 area percent epichlorohydrin, 6.4 area percent 2-methyl-2-pentenal, 6.5 area percent (10.0 weight percent) l,3-dichloro-2-propanol, 4.1 area percent 1,2,3-trichloropropane, and 46.0 area percent of 2,2'-oxybis(l- chloropropane).
• Hydrogen chloride gas (approximately 0.06 kg (60 grams)) from a lecture bottle on a balance is bubbled into the feed solution over about 3 hours. The clear solution turns yellow in color. The maximum temperature reached during the addition is 31 degrees Celsius.
• Gas chromatography (GC) analysis finds 11.8 area percent dichloropropane, 5.9 area percent epichlorohydrin, 6.4 area percent 2-methyl-2-pentenal, 19.7 area percent (27.6 weight percent) l,3-dichloro-2-propanol, 3.0 area percent 1,2,3-trichloropropane, and 45.6 area percent of 2,2'-oxybis(l-chloropropane).
• a minimum-boiling azeotrope is also predicted for the two component system of 1,3- dichloro-2-propanol and 1-decene ( Figure 3). Since the ether [2-chloro-l- (chloromethyl)ethoxy]-decane is of value for preparation of new surfactant products and is produced using 1-decene as raw material, using 1-decene also as a separating agent may be practical method to isolate DCP from the HCl-treated Crude PDC Bottoms stream (see Examples 2 and 3).
• Example 2 Case I: Conceptual scheme for azeotropic distillation of DCP using 1 -decene - process simulation
• a conceptual process flow scheme for purification of DCP from the HCl-treated PO/PG waste stream using 1-decene as an azeotropic entrainer is developed using ASPEN process simulation software version 2006.5.
• the Universal Functional Activity Coefficient (UNIFAC) predicted azeotropic composition of decene-DCP (47 mole percent DCP) is an equimolar ratio of decene to DCP in the final purified stream ( Figure 3), which would be a good feed composition for the reactive etherification process to produce the ether [2-chloro- l-(chloromethyl)ethoxy]-decane.
• Table 3 shows the composition of the feed stream following HC1 treatment.
• Column 1 is an azeotropic distillation column with 30 equilibrium contacting trays or stages, where 1 -decene entrains the DCP in the HCl-treated PO/PG waste stream and carries it overhead and the heavier boiling 2,2 '-oxybis(l -chloropropane) (bis-ether) is separated as a bottoms fraction.
• Predicted stream details for Column 1 are shown in Table 4.
• the Bottoms2 stream may be the feed for the reactive etherification to produce the ether [2- chloro-l-(chloromethyl)ethoxy]-decane.
• a makeup stream (about 28.2+4.6+5.8 kg/h) refurbishes the total 1-decene, which is entrained along with final DCP stream, the bis-ether bottoms from Column 1, and the overheads from Column 2. An overall recovery of 93.5 percent DCP is obtained. Stream details for Column 2 are shown in Table 5. It is worth noting here that only about 50 percent of the incoming TCP (impurity) is removed in the overheads, since 1-decene forms a minimum-boiling azeotrope with TCP as shown in Figure 4.
• the most significant impurity is predicted to be 1,2,3-trichloropropane, at approximately 4 weight percent.
• An overall recovery of 93.5 percent DCP and 98.2 percent 1-decene is predicted from the process simulation.
• An olefin (entrainer) to DCP in feed mass ratio of 0.3-1.5 is preferred for 1-decene as an entrainer.
• Example 3 Preparation and distillation purification of DCP from the Crude PDC Bottoms stream with 1 -decene as an azeotropic entrainer
• a 1-L jacketed bottom-drain glass reactor with an overhead stirrer and nitrogen bubbler is charged with 0.8453 kg (845.3 grams) of the Crude PDC Bottoms stream, and is cooled to 8 degrees Celsius using an attached recirculating heater / chiller.
• Hydrogen chloride gas (approximately 0.070 kg (70 grams)) from a lecture bottle on a balance is slowly bubbled in. The clear solution turns yellow in color. The maximum temperature reached during the addition is 40 degrees Celsius.
• 1-dodecene may also be used as an entrainer for DCP (see Figure 6).
• Column 1 is the azeotropic distillation column comprising 30 equilibrium contacting stages or trays, wherein 1-dodecene entrains the DCP in the HCl-treated feed stream (from Table 3) and carries it overhead, whereas the heavier boiling bis-ether is obtained as bottoms.
• Column 1 is operated at a design specification of 99 percent mass recovery of DCP in the overheads and 99.9 percent removal of the bis-ether from bottoms - which requires a reflux ratio (mass) of about 6 or a duty of 1.556 x 10 6 J/kg (1475 Btu/kg) HC1 treated stream.
• Stream details for Column 1 are shown in Table 8.
• Column 2 separates the lighter boiling impurities dichloropropane, epichlorohydrin, 2-methyl-2-pentenal, 1,2,3-trichloropropane - overheads and obtains 1-dodecene and DCP at the bottom.
• Column 2 consisting of 30 equilibrium contacting stages or trays is operated at a design specification of 99.5 percent recovery of the incoming 1-dodecene in the bottoms and 99.5 percent recovery of 1,2,3- trichloropropane in overheads. This requires a reflux ratio (mass) of about 12.1 or a duty of about 9.34 x 10 5 J/kg (885 Btu/kg) HC1 treated stream. Stream details for Column 2 are shown in Table 9.
• the stream Bottoms2 containing 1-dodecene and DCP is then cooled and sent to decanter wherein it separates into two liquid phases - the lighter phase containing 1-dodecene is recycled back and the heavier phase containing DCP is the purified product (see Table 10).
• the Bottoms2 stream may be the feed for the reactive etherification to produce the ether [2-chloro-l-(chloromethyl)ethoxy]-dodecane.
• a makeup stream (14.1 + 3.5 + 1 kg/h) refurbishes the 1-dodecene which is entrained along with final DCP stream, the bis-ether bottoms from Column 1, and overheads from Column 2. An overall recovery of 92 percent DCP is obtained.
• 1 -Dodecene has an advantage over 1-decene because when 1-dodecene is used as an entrainer, almost all of the 1,2,3-trichloropropane and 2-methyl-2-pentenal impurities are removed in the overhead stream. This is because TCP does not form an azeotrope with 1- dodecene (see Figure 7), as it does with 1-decene.
• a lower entrainer to feed ratio (mass) - about 0.4 - is required with 1 -dodecene, as compared to an entrainer to feed ratio (mass) of about 1 with 1-decene.
• the entrainer loss is also lower, and therefore a smaller makeup stream is required with 1 -dodecene.
• Example 5 Case III: 1 -Tetradecene as entrainer
• 1-tetradecene may also be used as an entrainer for DCP (see Figure 8), although it does not remove as much of the bis-ether.
• Column 1 is the azeotropic distillation column, wherein 1 -tetradecene entrains the DCP in the HCl-treated feed stream (from Table 3) and carries it overhead, whereas the heavier boiling bis-ether is obtained as bottoms.
• Column 2 separates the lighter boiling impurities 1,2-dichloropropane, epichlorohydrin, 2-methyl-2-pentenal, 1,2,3- trichloropropane in the overheads, and generates 1-tetradecene, DCP, and entrained bis-ether at the bottom.
• Column 2 consisting of 30 equilibrium contacting stages or trays, is operated at a design specification of 97.5 percent recovery of the incoming DCP in the bottoms and 99.5 percent recovery of 1,2, 3 -trichloropropane in overheads. This requires a reflux ratio (mass) of about 2.4, or a duty of about 2.43 x 10 5 J/kg (230 Btu/kg) HC1 treated stream (see Table 12).
• the stream Bottoms2 containing 1-tetradecene and DCP is then cooled and sent to decanter wherein it separates into two liquid phases, the lighter phase containing 1- tetradecene is recycled back and the heavier phase containing the purified DCP product (see Table 13).
• the Bottoms2 stream may be the feed for the reactive etherification to produce the ether [2-chloro-l-(chloromethyl)ethoxy]-tetradecane.
• the unrecovered bis-ether eventually appears in the final DCP stream (after phase separation), which is undesirable.
• a makeup stream (5.4 + 12.6 kg/h) refurbishes the 1 -tetradecene which is entrained along with final DCP stream, the bis-ether bottoms from Column 1, and the overheads from Column 2. An overall recovery of 96 percent DCP is obtained.
• Table 11 Column 1 process simulation details (1 -tetradecene as entrainer).
• Figure 9 shows the vapor pressure of 1 -octene as compared to the other species in the system.
• 1 -octene is an intermediate boiler, thus it would be obtained in the overheads of Column 2 along with 1,2-dichloropropane, epichlorohydrin and 2-methyl-2-pentenal, and would require an additional column for recovery and recycle.
• preferred entrainers would appear in the bottoms of Column 2 along with DCP, which may then be phase-separated and the entrainer recycled back to the azeotropic distillation column.
• 1 -octene can be used an entrainer, but it is not preferred.

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